This chapter explains how materials selection becomes much more difficult when designing for high-temperature corrosion environments. It also discusses the use of cladding and weld overlays to compensate for material deficiencies and prolong service life.

This chapter provides a detailed discussion on the definitions, alloy classification, alloy selection, mechanical properties, hot gas corrosion resistance, and formability of heat-resistant high alloy steels. In addition, the applications of cast heat-resistant alloys are also discussed.

This chapter presents the early classes of stainless steel. These include martensitic alloys, austenitic alloys, and ferritic alloys. It also presents stainless steel trade names. The chapter describes standardized designation for type 304 stainless steel by various specification organizations.

Steels that resist corrosive attack from normal atmospheric exposure and contain a minimum of 10.5% Cr and 50% Fe are generally classified as stainless steels. Their special qualities lie in a chromium-rich oxide surface film that quickly regrows when damaged. This chapter discusses the classification, composition, properties, treatments, and applications of austenitic, ferritic, martensitic, duplex, precipitation-hardening, powder metallurgy, and cast stainless steels. It also reviews the history of stainless steels and provides information on alloy designation systems.

This chapter describes the physical properties of steels used for castings. The properties covered include density, modulus of elasticity, Poisson's ratio, shear modulus, thermal expansion, thermal conductivity, specific heat, thermal diffusivity, electrical resistivity, and magnetic properties.

This article discusses the production, properties, and uses of high-alloy white irons. It explains how the composition and melt are controlled to produce a large volume of eutectic carbides, making these irons particularly hard and resistant to wear, and how the metallic matrix supporting the carbide phase can be adjusted via alloy content and heat treatment to optimize the balance between abrasion resistance and impact toughness. It also describes the effect of alloying elements and inoculants on various properties and behaviors and provides information on commercial alloy grades and applications.

This chapter is a collection of tables listing: cast alloy designations of Aluminum Association, along with their general applications; the chemical compositions of the frequently used alloys for gravity permanent molds, low-pressure permanent molds, squeeze castings, and die castings; the typical tensile properties of die cast alloys; and the designations of different heat treatments and their description. The tables also list the temperatures and times of typical heat treatment cycles for different permanent mold cast alloys; typical components in sand, gravity, and low-pressure permanent mold castings and die castings, the functional requirements of each process, and the corresponding suitable alloys and heat treatments; and alloys that are high vacuum die cast for structural castings. The chapter also presents examples of photomicrographs of some alloys cast by different processes.

This chapter describes the definitions, designation, chemical composition, room-temperature properties, elevated-temperature properties, and corrosion resistance of cast high alloy steels and stainless steels. In addition, the corrosion resistance of cast corrosion-resistant alloys is also covered.

Magnesium occupies the highest anodic position on the galvanic series and can be subject to severe corrosion. The corrosion problem is due to the impurity elements iron, nickel, and copper. However, the use of higher-purity magnesium alloys has led to corrosion resistance approaching that of some of the competing aluminum casting alloys. This chapter begins with a general overview of magnesium metallurgy and alloy designations and moves on to discuss in detail the nominal compositions, mechanical properties, heat treatment, fabrication, and corrosion protection of magnesium casting alloys and wrought magnesium alloys. It also discusses the nominal compositions, properties, and applications of commercially pure zinc, zinc casting alloys, and wrought zinc alloys.

This chapter covers the basics of weldability of cast steels such as carbon and low alloy steels, corrosion-resistant high alloy steels, nickel-base alloys, heat-resistant high alloy steels, and wear-resistant high austenitic manganese steels. It provides an overview of weld overlay and hard facing; cast-weld construction; and plasma arc cutting and plasma arc welding. The chapter discusses different types of welding processes. These include shielded metal-arc welding, air carbon arc cutting process, gas tungsten-arc welding, gas metal-arc welding process, flux-cored arc welding, submerged arc welding, and electroslag and electro-gas welding.

Aluminum has many outstanding properties, leading it to be used for a wide range of applications. It offers excellent strength-to-weight ratio, good corrosion and oxidation resistance, high electrical and thermal conductivity, exceptional formability, and relatively low cost. This chapter examines the metallurgy, composition, processing, and mechanical properties of aluminum and its alloys, both cast and wrought forms. It also covers heat treating and basic temper designations, including annealed, work hardened, solution heat treated, and solution heated treated and aged. The chapter concludes with information on corrosion and oxidation resistance.

Nickel-base castings are produced from a group of alloys with compositions that are typically greater than 50% Ni and less than 10% iron. This chapter presents the casting compositions of nickel-base alloys. It then provides an overview of heat treatment, mechanical properties, and applications of nickel-base castings.

With typical alloy systems, casting is often the most convenient method by which to produce components. This is true for stainless steels, both for corrosion-resisting and for heat-resisting applications. This chapter discusses stainless steel casting alloys and their metallurgy. Foundry methods are discussed to the degree they are specific to the stainless alloys.

This chapter provides basic engineering information on aluminum alloys with an emphasis on their use in applications where weight is a significant design factor. It discusses the advantages and limitations of various types of aluminum along with their compositions, designations, and achievable strengths. It explains how some alloys are hardened through solution strengthening and cold working, while others are strengthened by precipitation hardening. It also describes production and fabrication processes such as melting, casting, rolling, forging, forming, extruding, heat treating, and joining, and includes a section on the causes and effects of corrosion and how they are typically controlled.

This article discusses the composition, structures, properties, and behaviors of aluminum alloys and explains how they correspond to specific alloying elements. It begins with an overview of the general characteristics of wrought and cast aluminum alloys, the four-digit classification system by which they are defined, and the applications for which they are suited. It then explains how primary alloying elements, second-phase constituents, and impurities affect yield strength, phase formation, and grain size and how they induce structural changes that help refine certain alloys. The article also explains how primary alloying elements affect corrosion and wear behaviors and how they influence fabrication processes such as forming, forging, welding, brazing, and soldering.

This chapter defines steel castings, explains when to use steel castings, gives an overview of casting processes, and gives examples of suitable applications for cast steel parts.

The commercial relevance of cast irons is best understood in the context of the iron-carbon phase diagram, where their composition places them near the eutectic point, which sheds light on why they melt at lower temperatures than steel and why they can be cast into more intricate shapes. This chapter examines these unique properties and how they are derived. It begins by describing the basic metallurgy of cast iron, focusing on the eutectic reaction. It explains how to control the reaction and thus properties of cast iron by overcooling and inoculation. The chapter also discusses composition, microstructure, heat treatments, and the classification and casting characteristics of white, gray, ductile, malleable, compacted graphite, and special cast irons.

Aluminum is the second most widely used metal in the world. It is readily available, offers a wide range of properties, and can be shaped, coated, and joined using a variety of methods. This chapter discusses some of the key attributes of wrought and cast aluminum alloys and the classifications, designations, and grades of available product forms. It also explains how aluminum alloys are used in aerospace, automotive, rail, and marine applications as well as in building and construction, electrical products, manufacturing equipment, packaging, and consumer durables such as appliances and furniture.